Load floor assembly

ABSTRACT

A load floor assembly for a motor vehicle includes a core sandwiched between opposing hardboards. The core defines a slot with one of the hard boards that encircles a peripheral surface defined by the core and the opposing hardboards. A first fabric is adhered to the first hardboard and a second fabric is adhered to the second hardboard. The first fabric defines a first peripheral edge and a second fabric defines a second peripheral edge. Each of the first and the second peripheral edges are retained in the slot in an adhesive free manner.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 60/489,546 filed Jul. 23, 2003.

BACKGROUND OF THE INVENTION

The subject invention relates generally to an interior vehicle component, which provides a structural surface. More particularly, the present invention relates toward decorative surface treatment of the interior component.

The interior of motor vehicles, such as, for example, sport utility vehicles and station wagons, have trended toward improved functionality while not negatively affecting the overall mass and aesthetics of the vehicle. One such example is the inclusion of additional storage compartments located in the floor of the sport utility vehicle or station wagon. These storage compartments are concealed by a removable load floor, which must provide structural integrity to support the mass of heavy objects while being transported in the rear of the vehicle. It is desirable to provide a load floor having two surfaces, one surface that may be easily and used for transporting dirty materials, and a second surface covered with a decorative material, such as, for example, carpet, to provide a more elegant appearance.

Previous attempts to provide such a functional/aesthetically pleasing load floor have resulted in a peripheral edge that is unfinished and visibly unattractive. Occasionally, an additional covering is provided and completely conceals the load floor from the passenger compartment. Therefore, it would be desirable to produce a lightweight, functional load floor at a low cost having a finished peripheral surface that is aesthetically pleasing. One preferred method of providing a peripheral surface having an aesthetically pleasing appearance requires that a first fabric or decorative material and a second fabric or functional material be mated at the periphery where the perimeter edge of each of the materials is concealed in a slot. This presents various technical difficulties that have resulted in costly manufacturing processes to provide the desired aesthetically pleasing peripheral edge. One such example is disclosed in U.S. Pat. No. 5,061,002, Partition Plate for Automotive Vehicle, where a costly garnish molding is applied over the peripheral edge of an aesthetically pleasing fabric. Various other attempts have been made to provide an aesthetically pleasing peripheral edge to other components such as, for example, table top pads. U.S. Pat. No. 5,476,701 where adhesive is used to retain peripheral edges of a fabric covering a core within a slot. The application of adhesive in a narrow slot to retain fabric is known to be a difficult manufacturing process that is proven not viable due to the propensity of the adhesive to be spread over the visible surface of the table pad. Furthermore, forming a slot in a core material is known to require costly molding tools having sliding components, particularly for molded cores. As disclosed in U.S. Pat. No. 5,476,701, the slot is cut into the core with a common table saw, which is not practicable when manufacturing high production volumes.

Therefore, it would desirable to provide an improved load floor for an automotive vehicle having the functional flexibility of a decorative surface and a functional surface while providing an aesthetically pleasing peripheral edge at a low cost.

SUMMARY OF THE INVENTION

A load floor assembly for a motor vehicle includes a core sandwiched between opposing hard panels. A core defines a slot with one of the hard boards encircling a peripheral surface defined by the core and the opposing hard boards. A first fabric adhered to the first hard board and a second fabric adhered to the second hard board provides a visible surface to the load floor. The first fabric defines a first peripheral edge and the second fabric defines a second peripheral edge. Each of the first and the second peripheral edges are retained in the slot.

The aforementioned load floor assembly provides the benefit of both a functional surface and a aesthetically pleasing surface while further providing an aesthetically pleasing peripheral edge at a low cost. Forming a slot between the core and the hard board produces the same effect as either molding a slot in the core or cutting a slot in the core, both of which is known to be cost prohibitive. Therefore, the inventive load floor assembly provides the benefit of an aesthetically pleasing perimeter surface at a low cost that has not previously been available.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of the inventive interior component;

FIG. 2 shows a side view of the inventive interior component;

FIG. 3 shows an exploded view of the inventive interior vehicle component;

FIGS. 4-6 show partial side sectional views of the assembly process of the interior vehicle component; and

FIGS. 7 and 8 show an apparatus used to assemble the interior vehicle component.

DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, an inventive vehicle assembly such as, for example, a load floor is generally shown at 10. The assembly 10 includes a functional surface 12 and a decorative surface 14. The load floor assembly is typically used in the rear of a station wagon or sport utility vehicle to cover a compartment used for storage while providing structural support capable of supporting of heavy objects being transported in the vehicle.

Preferably, the functional surface 12 is formed from a polymeric fabric 13 (FIG. 3) such as, for example, vinyl or other easily cleanable material for removing contaminants. Furthermore, the decorative surface 14 is formed from a carpet or equivalent decorative fabric 15 (FIG. 3) and is exposed for aesthetically appearance when not hauling contaminated materials in the rear of the vehicle. The functional fabric 13 and the decorative fabric 15 form a seam 16 along a peripheral surface 18 of the assembly 10. The seam 16 provides an aesthetically pleasing transition between the functional surface 12 and the decorative surface 14.

Referring now to FIG. 3, an exploded view of the assembly 10 is shown, where each of the various components are represented. A core 20 is formed as a generally planar sheet panel. Preferably, the core if formed from a foamed or equivalent light weight material, such as, for example, polystyrene, providing a desirable dimensional configuration to the assembly 10. A top surface 22 of the core 20 includes a stepped perimeter surface 24 that is spaced from the top surface 22, the purpose of which will be explained further below. The core 20 is preferably formed of a low density material to reduce the mass of the assembly 10. However, most low density materials do not provide the structural integrity required of a load floor of an automotive vehicle. Therefore, a second sheet of material 26 is formed as a generally planar panel having a first surface 28 that is matable to the top surface 22 of the core 20. The second sheet of material is preferably formed from a hard board or equivalent rigid substrate to provide further structural integrity to the assembly 10. Other substrates such as, for example, rigid polymeric materials may also be selected such as, for example, polyvinylchloride, reinforced polypropylene, or other equivalent extruded materials may be selected. A third sheet of material 30 is optionally mated to an opposite side of the core 20 from the second sheet of material 26. Therefore, the core 20 is sandwiched between the second sheet of material 26 and the third sheet of material 30. Preferably, the third sheet of material 30 is formed from the same substrate as the second sheet of material 26 to provide manufacturing efficiencies.

Referring now to FIGS. 4 through 6, the assembly process for forming the seam 16 in the assembly 10 is sequentially shown. The core 20 and the second and third sheets of material 26, 30 are adhered together by an adhesive 32. The functional surface 12 is formed from the functional fabric 13 and adhered to either the second sheet of material 26 or the third sheet of material 30 with the adhesive 32 that is applied over the outer surface of either the second or third sheet of material 26, 30. The decorative fabric 15 is adhered to an outer surface of the opposing sheet of material 26, 30 from the sheet of material 26, 30 that the functional fabric 13 is adhered to. Similar to the process stated above, adhesive 32 is applied to the outer surface to adhere the decorative surface 14 to the assembly 10.

The core 20 and the first and second sheets of material 26, 30 define a peripheral surface 34 of the assembly 10. Preferably, the edges of the core 20 and the second and third sheets of material 26, 30 defining the peripheral surface 34 are generally in the same plane. However, it is not functionally necessary that the edges of the core 20 and the second and third sheets of material 26, 30 be in the same plane. It should be understood, that in one preferred embodiment, adhesive 32 is applied to the peripheral surface 34. However, it is not necessary that the adhesive 32 be applied to the entire peripheral surface 34 or to the peripheral surface at all.

The second sheet of material 26 forms a slot 36 with the perimeter surface 24 of the core 20. The preferred width of the slot 36 is generally less than the thickness of the functional surface 12 in combination with the decorative surface 14. It is preferred, and even desirable, to prevent the adhesive 32 from filling or coming into contact with the slot 36.

As best represented in FIG. 5, the functional fabric 13 includes a functional peripheral edge 38 and the decorative fabric 15 includes a decorative peripheral edge 40. Each edge 38, 40 is forced into the slot 36 by a wheel like device 42 or similar blade. As shown in FIG. 6, each edge 38, 40 is retained in the slot 36 in an adhesive free manner. It should be further understood, that frictional forces provide adequate retention pressure upon each peripheral edge 38, 40 to retain the peripheral edges 38, 40 in the slot in the absence of adhesive 32. The application of adhesive to the peripheral surface 34 of the assembly 10 provides additional retention to the edges 38, 40 when necessary.

Referring now to FIGS. 7 and 8, an apparatus 44 is used to form the seam between the second and third sheets of material 26, 30. A work surface 46 supports generally parallel tracks 48 on which a frame 50 is slideably supported. The frame 50 supports the assembly 10 in a horizontal orientation. Once the decorative surface and the peripheral surface have been adhered to the outer sides of the second and third sheets of material 26, 30, the assembly 10 is placed upon the frame 50. A rolling device 52 is placed upon opposite sides of the tracks 48. At least one wheel 42 is rotatably positioned on the rolling device 52 and is received by the slot 36 defined in the assembly 10. Initially, the frame 50 is slid along the opposing tracks 48 so that the assembly 10 engages the wheels 42 of the rolling devices 52. The wheels 42 force the functional edge 38 and the decorative edge 40 into the slot 36 as discussed above. Prior to engagement with the wheels 42, the peripheral surface 34 of the assembly 10 abuts the rolling device 52 and engages a cam 54 to force the peripheral edges 38, 40 of the functional fabric 13 and the decorative fabric 15 against the peripheral surface 34 of the assembly 10 locating the peripheral edges 38, 40 in a position that facilitates tucking the peripheral edges 38, 40 into the slot 36 with the wheels 42.

A forward rotating device 56 is slideably retained upon a forward rail 58, which is moveable in a generally perpendicular relationship to the tracks 48. The forward rotating device 56 rotatably supports a wheel 42 to tuck the peripheral edges 38, 40 of the functional fabric 13 and the decorative fabric 15 into the slot 36 along a leading edge of the assembly 10.

A rear rotating device 60 is disposed at rear end 62 of the frame 50. Typically, the rear end of the assembly 10 is contoured to match a rear end (not shown) of the vehicle interior. Therefore, the rear rotating device 60 preferably slides along a contoured track 64 designed to match the rear end of the assembly 10. The rear rotating device 60 supports a wheel 42 similar to as described above to mate with the slot 36 of the assembly for tucking the functional peripheral edge 38 and the decorative peripheral edge 40 therein. Of course, the forward end of the assembly 10 may also include a contoured shape, which will require the forward rotating device 56 to also move along a contour track.

As best shown in FIG. 8, a plurality of rollers 66 are spaced above the assembly 10 to force the assembly downward for retaining the assembly 10 on the frame 50 during the rolling operation which tucks the peripheral edges 38, 40 into the slot 36. Two rows of rollers 64 each having three rollers 64 per roll are shown. However, more rollers 66 may be added as necessary.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described. 

1. A structural assembly for a vehicle, comprising: a generally planar first sheet of material providing structural properties to said structural assembly; a generally planar second sheet of material having a first surface matable with said first sheet of material, wherein said first surface defines a stepped perimeter surface spaced from said first surface thereby defining a peripheral slot with said first sheet of material; a first fabric and a second fabric wrapped around said structural assembly, each of said fabrics including a fabric periphery folded into said peripheral slot, and wherein said peripheral slot retains said fabric periphery of said first fabric and said second fabric with frictional forces.
 2. An assembly as set forth in claim 1, wherein said slot defines a slot width less than a combination of first thickness defined by said first fabric and a second thickness defined by said second fabric.
 3. An assembly as set forth in claim 1, comprising a generally planar third sheet of material providing structural properties to said assembly and being mated to an opposite side of said second sheet of material from said first sheet of said material.
 4. An assembly as set forth in claim 3, wherein said first sheet of material and said second sheet of material comprise hard board.
 5. An assembly as set forth in claim 4, wherein said first, second, and third sheets of material each define a peripheral surface.
 6. An assembly as set forth in claim 5, wherein said first fabric and said second fabric are adhered to said assembly with an adhesive.
 7. An assembly as set forth in claim 6, wherein said adhesive is applied to said peripheral surfaces defined by said first, second, and third sheets of material.
 8. An assembly as set forth in claim 1, wherein said first fabric comprises a durable material and said second fabric comprises an esthetically pleasing material.
 9. An assembly as set forth in claim 1, wherein said second sheet of material is adhered to said first and said third sheets of material with an adhesive.
 10. An assembly as set forth in claim 1, wherein said peripheral edge of said first fabric and said second fabric are retained in said slot without adhesive.
 11. A load floor assembly for a motor vehicle, comprising; a core sandwiched between opposing hardboards, wherein said core defines a slot with one of said hard boards encircling a peripheral surface defined by said core and said opposing hardboards; a first fabric adhered to said first hardboard and a second fabric adhered to said second hardboard; and said first fabric defining a first peripheral edge and a second fabric defining a second peripheral edge, each of said first and said second peripheral edge retained in said slot in an adhesive free manner.
 12. An assembly as set forth in claim 11, wherein said first fabric includes a first thickness and said second fabric includes a second thickness.
 13. An assembly as set forth in claim 12, wherein said slot defines a width being thinner than a combination of said first thickness of said first fabric and said second thickness of said second fabric thereby retaining said peripheral edges of said first fabric and said second fabric therein.
 14. An assembly as set forth in claim 1, wherein an adhesive is applied to said peripheral surface defined by said core and said opposing hardboards thereby retaining said first fabric and said second fabric to said peripheral surface.
 15. A method of assembling a load floor of a motor vehicle; comprising the steps of: providing a core being generally planar; providing a mating member being generally planar; adhering said core to said mating member thereby forming a peripheral surface defined by said mating member and said core; forming a slot between said mating member and said core; applying a first fabric and a second fabric to said assembly, each fabric defining a outer edge; and forcing first outer edge of said first fabric and said second fabric into said slot thereby retaining said first fabric and said second fabric in said slot in an adhesive free manner.
 16. A method as set forth in claim 15, further including the step of applying an adhesive to said peripheral surface defined by said core and said mating member.
 17. A method as set forth in claim 16, further including the step of forming a notch in said core thereby forming a first side of said slot.
 18. A method as set forth in claim 15, further including the step of providing a wheel for inserting said peripheral edge of said first and said second fabric in said slot.
 19. A method as set forth in claim 18, further including the step of rolling said wheel along said slot thereby forcing said peripheral edge of said first and said second fabric in said slot. 